How do you calculate production efficiency?
11 Answers Answer
Efficiency of measure of resource utilization ratio. In simple terms it is Outputs/Inputs.
It can be any resource - Time, Material, Manpower, Machine, etc.
Depending the resource you are measuring and unit you are using, you should be able to measure the efficiency. In production also, you should be able to measure -
Good product / Mateial used (Units can be Kgs, Nos, etc)
Equipment utilization = No of hours produced / No of hours available
OEE is a parameter, which helps production department to understand overall effectiveness - This covers Quality, Maintenance, Production parameters and gives one index.
This can be measured for single machine as well as for the overall plant.
This is with example hope give you better clearity.
OEE – Overall Equipment Efficiency is Comparison between “actual output” and “should-be output”.
Availability Rate X Productive Rate X Quality Rate
i.e Scheduled Loading Time =60 Min X8 Hrs –40 Min =440 Minutes
(40 Minute is break time)
Available Time =440 –80 Minute =360 Minutes
80 Minutes lost due to changeover (45 min), Breakdown & Repair (25 min), Broken Tool Replace (10 Min)
Productive Rate =420 pcs produced X40 Sec/pc
(40 sec/pc is engineered cycle time) =16800 sec /60 =280 Min of Productive Time
Availability Rate = (Available Time / Scheduled Time) =360 /440 =0.82 =82 %
Productive Rate = (Productive Time / Available Time) =280 /360 =0.78 =78 %
Quality Rate = (Acceptable Quantity / Total Quantity) = (420 -30) /420 =390 /420 =0.93 =93 %
OEE =0.82 X0.78 X0.93 =0.5848 =59.48 %
Production efficiency=( O/P)/ Machine capacity
Production efficiency=( Production hours/ Available hours)xmachine capacity
Production efficiency= Qty produced/ planned qty
Production efficiency= Machine utilization /machine capacity
Actually I was looking for an answer which relates the production downtime to the production efficiency. The production down time is caused by production personnel & does not include technical down time, it includes start up, shut down, change of product size or type on a production line or machine, etc...
In order to calculate a production line efficiency you need to obtain data of the number of pieces and the number of hours worked. In addition, you will also need to obtain the piece/min data by conducting a time study at the front and end of line (ensure that they are equal). Following the collection of this data you can approach it in this manner: Number of pieces total / number of minutes of production= Avg. pieces per min Now... take your (Avg pieces per min/actual piece per min count) x100= efficiency percentage
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